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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

James Webb Space Telescope (JWST) Integrated Sciene Instrument Module (ISIM) Cryo-Vac 3 (CV3) Thermal Vacuum Test

This presentation describes the test objectives, test summary, test configuration and test performance of the James Webb Space Telescope Integrated Science Instrument Module CryoVac 3 Thermal Vacuum Test. Verify the ISIM System in its final configuration after environmental exposure and provide a post-environmental performance baseline, including critical ground calibrations needed for science data processing in flight.

Thermal Vacuum Testing↗
NASA NTRS1983

Experimental measurements of material damping in free fall with tuneable excitation

An experimental method of measuring material damping of a specimen in free fall has been developed. An initially simply-supported test specimen was simultaneously excited and lofted into free fall with a spring-mass launcher. The launcher could be tuned to produce varying initial stress amplitude levels in the specimens. Damping information was obtained from the transient response of the specimens while in free fall in a vacuum. A dynamic model of the launch process was developed which indicates the range of frequency and initial specimen stress amplitude over which tests can be performed. To verify the facility, material damping was measured in 2024-T3 aluminum, and (+ or - 45)2s AS1/3501-6 graphite/epoxy. Free-free frequencies ranged from 20-357 Hz in aluminum, and from 18-171 Hz in the (+ or - 45)2s specimens. Damping values in aluminum were found to be close to theoretical values and independent of stress levels below 130 MPa (18.7 Ksi). Damping ratios in the (+ or - 45)2s graphite/epoxy specimens were found to be largely independent of stress levels below 43.8 MPa (6.35 Ksi) and only slightly dependent on frequency. A small dependence of the frequency of free vibration on specimen stress amplitude was also noted.

Crawley, E. F.↗
NASA NTRS1983

Reduction, partial evaporation, and spattering - Possible chemical and physical processes in fluid drop chondrule formation

The major chemical differences between fluid drop chondrules and their probable parent materials may have resulted from the loss of volatiles such as S, H2O, Fe, and volatile siderophile elements by partial evaporation during the chondrule-forming process. Vertical access solar furnace experiments in vacuum and hydrogen have demonstrated such chemical fractionation trends using standard rock samples. The formation of immiscible iron droplets and spherules by in situ reduction of iron from silicate melt and the subsequent evaporation of the iron have been observed directly. During the time that the main sample bead is molten, many small spatter spherules are thrown off the main bead, thereby producing many additional chondrule-like melt spherules that cool rapidly and generate a population of spherules with size frequency distribution characteristics that closely approximate some populations of fluid drop chondrules in chondrites. It is possible that spatter-produced fluid drop chondrules dominate the meteoritic fluid drop chondrule populations. Such meteoritic chondrule populations should be chemically related by various relative amounts of iron and other volatile loss by vapor fractionation.

King, E. A.↗
NASA NTRS1988

Cold-Worked Inconel(R) 718 Bars

Cold working and double aging yield high strength without sacrifice of resistance to corrosion. Report presents data on mechanical properties and stress-corrosion resistance of triple-melted, solution-treated, work-strengthened, direct-double-aged Inconel(R) 718 alloy. Triple melting consists of vacuum induction melting, electro-slag remelting, and vacuum arm remelting. Data indicate advance in processing of large-diameter bars. New process increases yield strength without reducing the elongation, reduction of area, and grain size.

Montano, J. W.↗
NASA NTRS1988

On the expansion of ionospheric plasma into the near-wake of the Space Shuttle Orbiter

During the Spacelab 2 mission, while the Plasma Diagnostics Package was attached to the Remote Manipulator System, differential ion vector measurements were obtained in the near wake at a distance of 4-5 Shuttle radii. The Orbiter's wake was found to fill in at a much faster rate than can be explained by simple thermal motion. The measurements strongly suggest that filling of the Orbiter's wake is produced by the process of 'collisionless plasma expansion into a vacuum' and that, for oblique angles of the magnetic field and velocity vectors, the near wake plasma depletion a few radii downstream is not sensitive to the body scale size.

Stone, N. H.↗
NASA NTRS1990

Installing scientific instruments into a cold LHe dewar - The Gravity Probe B approach

Gravity Probe B is an orbital test of Einstein's general theory of relativity using gyroscopes. The precession of the gyroscopes will measure both the geodetic effect (6.6 arcsec/yr) through the curved space-time surrounding the earth and the motional effect (0.042 arcsec/yr) due to the rotating earth dragging space-time around with it. To achieve the extraordinary accuracies needed to measure these small precessions, it is necessary to have the gyroscopes operating in the following environments: a vacuum of less than 10 exp -10 torr; an acceleration level of less than 10 exp -10 g's; a magnetic field of less than 10 exp -7 gauss; and a temperature near 2 K. This paper discusses designs that allow scientific instruments to be installed into a dewar at 4.2 K. Methods for structurally supporting the instruments, transferring heat across joints at low temperature in vacuum, and excluding air during the insertion process are discussed. The structural support method is designed for Shuttle launch loads.

Parmley, Richard T.↗
NASA NTRS1992

The coalescence instability in collisionless plasmas

The process whereby magnetic island structures tend to merge into larger units is known as magnetic island coalescence. This coalescence process is investigated for the case of a collisionless plasma by means of 2D particle simulations. The pairwise merging of a preformed island chain leads to a gentle redistribution of the density and current density profiles. The nonlinear evolution of the collisionless tearing instability in a long system is found to lead to a much more violent coalescence process resulting in the formation of a vacuum X region. This stage is characterized by enhanced growth rates for the long-wavelength modes that exceed the maximum linear tearing growth rate, super-Alfvenic flows away from the reconnection X line, substantial bulk heating in the parallel direction, and the formation of energetic particle tails in the direction of the inductive electric field.

Pritchett, P. L.↗
NASA NTRS1994

The realuminizing of the 7-meter-diameter solar simulator collimating mirror

This paper describes the modification of a three-electron-beam (EB) gun system for vacuum depositing a highly reflective aluminum coating on a 7.01-m (23-ft) -diam nickel-plated aluminum collimating mirror. The mirror is part of the JPL 7.62-m space simulator that was recently modernized with a new high vacuum pumping system, solar lamp power supplies, solar optic lens system, and refurbished collimating mirror. The 7.01-m 12,700-kg (14-ton) spherical collimating mirror was removed from this facility for replating with 381 micron (0.015 in.) of electroless nickel and polished to a specular finish for realuminizing. The space chamber served as the vacuum coating vessel for the realuminizing coating process. The mirror is the primary reflector for the solar simulation system and the aluminized reflective surface is its most critical performance element. The uniformity of thickness and high reflectivity of the coating in visible and near-ultraviolet (UV) light governs the accuracy of the beam for solar testing. The uniformity of the thin-film thickness also controls the durability of the mirror over time. The mirror was polished to a 64-percent reflectivity with a uniformity of 1.5 percent. The performance goal for the aluminizing was 89 percent with +/- 0.5-percent variation over the mirror.

Noller, E. W.↗
NASA NTRS1999

Precise Frequency Measurements Using a Superconducting Cavity Stabilized Oscillator

Many physics experiments call on improved resolution to better define the experimental results, thus improving tests of theories. Modern microwave technology combined with high-Q resonators can achieve frequency readout and control with resolutions up to a part in 10(exp 18). When the physical quantity in question in the experiment can be converted to a frequency or a change in frequency, a high-stability microwave oscillator can be applied to obtain state-of-the-art precision. In this work we describe the overall physical concepts and the required experimental procedures for optimizing a high-resolution frequency measurement system that employs a high-Q superconducting microwave cavity and a low-noise frequency synthesizer. The basic approach is to resolve the resonant frequencies of a high-Q (Q > 10(exp 10)) cavity to extremely high precision (one part in 10(exp 17)- 10(exp 18)). Techniques for locking the synthesizer frequency to a resonant frequency of the superconducting cavity to form an ultra-stable oscillator are described. We have recently set up an ultra-high-vacuum high-temperature annealing system to process superconducting niobium cavities, and have been able to consistently achieve Q > 10(exp 9). We have integrated high-Q superconducting cavities with a low-noise microwave synthesizer in a phase-locked-loop to verify the frequency stability of the system. Effects that disturb the cavity resonant frequency (such as the temperature fluctuations and mechanical vibrations) and methods to mitigate those effects are also considered. Applicability of these techniques to experiments will be discussed, and our latest experimental progress in achieving high-resolution frequency measurements using the superconducting-cavity-stabilized-oscillator will be presented.

Strayer, D. M.↗
NASA NTRS2001

Determination of the Accommodation Coefficient Using Vapor/gas Bubble Dynamics in an Acoustic Field

Nonequilibrium liquid/vapor phase transformations can occur in superheated or subcooled liquids in fast processes such as in evaporation in a vacuum. The rate at which such a phase transformation occurs depends on the "condensation" or "accommodation" coefficient, Beta, which is a property of the interface. Existing measurement techniques for Beta are complex and expensive. The development of a relatively inexpensive and reliable technique for measurement of Beta for a wide range of substances and temperatures is of great practical importance. The dynamics of a bubble in an acoustic field strongly depends on the value of Beta. It is known that near the saturation temperature, small vapor bubbles grow under the action of an acoustic field due to "rectified heat transfer." This finding can be used as the basis for an effective measurement technique of Beta. We developed a theory of vapor bubble behavior in an isotropic acoustic wave and in a plane standing acoustic wave. A numerical code was developed which enables simulation of a variety of experimental situations and accurately takes into account slowly evolving temperature. A parametric study showed that the measurement of Beta can be made over a broad range of frequencies and bubble sizes. We found several interesting regimes and conditions which can be efficiently used for measurements of Beta. Measurements of Beta can be performed in both reduced and normal gravity environments.

Gumerov, Nail A.↗
NASA NTRS2012

Adhesion in a Vacuum Environment and its Implications for Dust Mitigation Techniques on Airless Bodies

During the Apollo missions, the adhesion of dust to critical spacecraft systems was a greater problem than anticipated and resulted in functional degradation of thermal control surfaces, spacesuit seals, and other spacecraft components. Notably, Earth-based simulation efforts did not predict the magnitude and effects of dust adhesion in the lunar environment. Forty years later, we understand that the ultrahigh vacuum (UHV) environment, coupled with micrometeorite impacts and constant ion and photon bombardment from the sun result in atomically clean and high surface energy dust particles and spacecraft surfaces. However, both the dominant mechanism of adhesion in airless environments and the conditions for high fidelity simulation tests have still to be determined. The experiments presented in here aim to aid in the development of dust mitigation techniques for airless bodies (e.g., lunar surface, asteroids, moons of outer planets). The approach taken consists of (a) quantifying the adhesion between common polymer and metallic spacecraft materials and a synthetic noritic volcanic glass, as a function of surface cleanliness and of triboelectric charge transfer in a UHV environment, and (b) determining parameters for high fidelity tests through investigation of adhesion dependence on vacuum environment and sample treatment. Adhesion force has been measured between pins of spacecraft materials and a plate of synthetic volcanic glass by determining the pull-off force with a torsion balance. Although no significant adhesion is generally observed directly as a result of high surface energies, the adhesion due to induced electrostatic charge is observed to increase with spacecraft material cleanliness, in some cases by over a factor of 10. Furthermore, electrostatically-induced adhesion is found to decrease rapidly above pressures of 10-6 torr. It is concluded that high-fidelity tests should be conducted in high to ultrahigh vacuum and include an ionized surface cleaning process.

Berkebile, Stephen↗
NASA NTRS2016

CryoCart Restoration and Vacuum Pipe Construction

Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.

Chaidez, Mariana↗
NASA NTRS1992

Application of programmable logic controllers to space simulation

Incorporating a state-of-the-art process control and instrumentation system into a complex system for thermal vacuum testing is discussed. The challenge was to connect several independent control systems provided by various vendors to a supervisory computer. This combination will sequentially control and monitor the process, collect the data, and transmit it to color a graphic system for subsequent manipulation. The vacuum system upgrade included: replacement of seventeen diffusion pumps with eight cryogenic pumps and one turbomolecular pump, replacing a relay based control system, replacing vacuum instrumentation, and upgrading the data acquisition system.

Sushon, Janet↗
NASA NTRS1986

Carbon monoxide production in low energy oxygen ion bombardment of pyrolytic graphite and Kapton surfaces

The results of an investigtion of the interaction of low energy oxygen ions with pyrolytic graphite and Kapton surface are reported. CO molecules emitted from the surface as a result of the ion bombardment were detected by a mass spectrometer. Because the ion-induced signals were small compared to that arising from the CO background pressure in the vacuum system, the ion beam was modulated and the modulated component of the CO signal measured with a lock-in amplifier. The quantum yield (CO molecules emitted per incident oxygen ion) for graphite rose from 1.9 at 4.5 eV ion energy to 6.6 at 465 eV. Comparable yields were obtained for Kapton. The large size of the yields suggests contributions to the reaction process from the background O2 molecules in the vacuum system.

Horton, C. C.↗
NASA NTRS1971

Alloyed coatings for dispersion strengthened alloys

Processing techniques were developed for applying several diffusion barriers to TD-Ni and TD-NiCr. Barrier coated specimens of both substrates were clad with Ni-Cr-Al and Fe-Cr-Al alloys and diffusion annealed in argon. Measurement of the aluminum distribution after annealing showed that, of the readily applicable diffusion barriers, a slurry applied tungsten barrier most effectively inhibited the diffusion of aluminum from the Ni-Cr-Al clad into the TD-alloy substrates. No barrier effectively limited interdiffusion of the Fe-Cr-Al clad with the substrates. A duplex process was then developed for applying Ni-Cr-Al coating compositions to the tungsten barrier coated substrates. A Ni-(16 to 32)Cr-3Si modifier was applied by slurry spraying and firing in vacuum, and was then aluminized by a fusion slurry process. Cyclic oxidation tests at 2300 F resulted in early coating failure due to inadequate edge coverage and areas of coating porosity. EMP analysis showed that oxidation had consumed 70 to 80 percent of the aluminum in the coating in less than 50 hours.

Wermuth, F. R.↗
NASA NTRS1992

Anodized aluminum coatings for thermal control. I - Coating process and stresses

Anodized aluminum is a candidate material for use as a thermal radiator surface on Space Station Freedom. Here, results of measurements of coating stress at room temperature are presented. The effects of coating process conditions and also subsequent exposure to different humidities, from above ambient to vacuum, are reported. The most important observation with regard to space applications is that the coating stress is very dependent on humidity, changing from compressive at ambient humidity to strongly tensile in 10 exp -6 torr vacuum. The increase in stress is accompanied by loss of water from the coating, and the process is reversible.

Alwitt, R. S.↗
NASA NTRS1985

Vacuum MOCVD fabrication of high efficience cells

Vacuum metal-organic-chemical-vapor-deposition (MOCVD) is a new fabrication process with improved safety and easier scalability due to its metal rather than glass construction and its uniform multiport gas injection system. It uses source materials more efficiently than other methods because the vacuum molecular flow conditions allow the high sticking coefficient reactants to reach the substrates as undeflected molecular beams and the hot chamber walls cause the low sticking coefficient reactants to bounce off the walls and interact with the substrates many times. This high source utilization reduces the materials costs power device and substantially decreases the amounts of toxic materials that must be handled as process effluents. The molecular beams allow precise growth control. With improved source purifications, vacuum MOCVD has provided p GaAs layers with 10-micron minority carrier diffusion lengths and GaAs and GaAsSb solar cells with 20% AMO efficiencies at 59X and 99X sunlight concentration ratios. Mechanical stacking has been identified as the quickest, most direct and logical path to stacked multiple-junction solar cells that perform better than the best single-junction devices. The mechanical stack is configured for immediate use in solar arrays and allows interconnections that improve the system end-of-life performance in space.

Partain, L. D.↗
NASA NTRS2011

Characterization of Electron Beam Free-Form Fabricated 2219 Aluminum and 316 Stainless Steel

Researchers at NASA Langley Research Center have developed an additive manufacturing technology for ground and future space based applications. The electron beam free form fabrication (EBF3) is a rapid metal fabrication process that utilizes an electron beam gun in a vacuum environment to replicate a CAD drawing of a part. The electron beam gun creates a molten pool on a metal substrate, and translates with respect to the substrate to deposit metal in designated regions through a layer additive process. Prior to demonstration and certification of a final EBF3 part for space flight, it is imperative to conduct a series of materials validation and verification tests on the ground in order to evaluate mechanical and microstructural properties of the EBF3 manufactured parts. Part geometries of EBF3 2219 aluminum and 316 stainless steel specimens were metallographically inspected, and tested for strength, fatigue crack growth, and fracture toughness. Upon comparing the results to conventionally welded material, 2219 aluminum in the as fabricated condition demonstrated a 30% and 16% decrease in fracture toughness and ductility, respectively. The strength properties of the 316 stainless steel material in the as deposited condition were comparable to annealed stainless steel alloys. Future fatigue crack growth tests will integrate various stress ranges and maximum to minimum stress ratios needed to fully characterize EBF3 manufactured specimens.

Ekrami, Yasamin↗